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Jacqueline Isaacs Associate Director, Center for High‐rate Nanomanufacturing
Northeastern University, Boston MA
The 10th U.S.‐Korea Forum on Nanotechnology Boston, MA USA
October 15‐16, 2013
How can we ensure nanomanufacturing processes and products remain safe for workers, consumers and the environment?
How can industry develop
new technologies in a responsible, sustainable manner?
NSF Scalable Nanomfg Award #1120329
Lead Institution: NEU Collaborators at Yale, Harvard, UMass Lowell
Project focuses on applications with CNTs ◦ Composites (EMI shielding) ◦ Batteries ◦ Sensors
Isaacs, Bosso, Busnaina, Cullinane, Eckelman, Sandler : Northeastern
Mead, Bello: U Mass Lowell Zimmerman: Yale
Nash: Harvard
Methodology to evaluate the environmental effects and potential impacts of… ◦ Product ◦ Process ◦ Activity
From raw materials acquisition through production, use and disposal
Where do nano‐enabled products contact people?
Where would nano products contact the environment?
Any means for estimating quantities at points of contact?
SWNT Switch Sensors
EMI‐Shielding Batteries
Busnaina and Somu, Northeastern University
1. Components of batteries • Cathodes • Anodes • Separator and electrolyte
2. Batteries classification • Primary or non‐rechargeable • Secondary or rechargeable
Mixing
Coating & Drying
Calendaring
Cutting
Assembly
Filling
Sealing
Forming & Testing
NMP Anode AM Cathode AM Carbon Black PVDF
Al Sheet Cu Sheet
Separator
Electrolyte
High Protection Environment
Desired
Clean Room Environment
CNT
Templates Nanoelements Assembly Processes
Transfer Processes Substrates Applications
Microwires template Nanoparticles Electrophoretic
2-D and 3-D Direct transfer (no functionalization) Silicon
SWNT switch for memory
devices
Nanowires templates
Carbon nanotubes
(SWNTs and MWNTs)
Chemical Functionalization
Direct transfer with chemical
functionalization Polymer Polymer-based
Biosensors
Nanotrench template
Conductive polymers
(PANi)
Electrophoretic and chemical
functionalization
No transfer needed Metal
Nanoparticle-based
Biosensors
Template-free Polymer blends Dielectrophoretic 2-D and 3-D
Reel-to-reel transfer
SWNT
Batteries
Damascene Template Fullerenes Convective Switchable
functionalization Photovoltaics
Acenes Convective interfacial
SWNT Chem Sensors
Graphene Self assembly EMI Shielding
CHN Toolbox Connects Research to Applications
Templates Nanoelements Assembly Processes
Transfer Processes Substrates Applications
Microwires template Nanoparticles Electrophoretic Direct transfer (no
functionalization) Silicon SWNT switch for memory
devices
Nanowires templates
Carbon nanotubes
(SWNTs and MWNTs)
Chemical Functionalization
Direct transfer with chemical
functionalization Polymer Polymer-based
Biosensors
Nanotrench template
Conductive polymers
(PANi)
Electrophoretic and chemical
functionalization
No transfer needed Metal
Nanoparticle-based
Biosensors
Template-free Polymer blends Dielectrophoretic Reel-to-reel transfer
CNT Batteries
Damascene Templates Fullerenes Convective Switchable
functionalization Photovoltaics
Acenes Convective interfacial
SWNT Chem Sensors
Graphene Self assembly EMI Shielding
Shah, Kotz, Somu and Busnaina, Northeastern University
1- Material preparation
2- Cutting the Aluminum
3- Treating the surface
7- Electrophoresis assembly
8- Clean up
4- Preparing CNT solution
9- Additional layer MWCNT
11- Additional layer LiMnO
6- Inspection
5- Directed assembly (Spinning)
10- Inspection
ENERGY kWh1.073657
INPUT MATERIAL g/chipethanol (200 proof) 15.78Lithium Manganese Oxide Powder 0.1Gold Chip 0.5576N2 Gas 10.324ethylene glycol 0.446deionized water 5163.95disposable lab materials (plastic and paper 10.48MWCNT 0.00112INPUT TOTAL 5201.639
OUTPUT MATERIAL g/chipmixed wastewater to treatment 5174.364hazardous waste 16.276emissions to air 10.324MWCNT 0.00112OUTPUT TOTAL 5200.964
SimaPro Software: Nanobattery Cathode Labscale Fabrication
Cathode normalized result indicate three greatest contributors:
• Respiratory inorganics • Land use • Fossil fuels
Nanobattery Cathode Labscale Fabrication
Hakimian and Isaacs, Northeastern University
Results do not indicate effect of CNTs due to
limited toxicological information…
Same issues as in 2007, 2009…
CF = EF * FF * XF Characterization
Factor
Effect, Fate, Exposure
Eckelman, Mauter, Isaacs, and Elimelech, New Perspectives on Nanomaterial Aquatic Ecotoxicity: Production Impacts Exceed Direct Exposure Impacts for CNTs, Enviro Sci Tech, 2012
Alternatives for final disposition: • Landfill – Most household batteries – 87% of all waste batteries
• Stabilization – Prior to landfill – Not used in general
• Incineration – Municipal waste combustion facilities
• Recycling – High temperature processes – Percentage depends on battery type
Espinoza and Isaacs, Northeastern University
Source: Recycling Laws Map http://www.call2recycle.org/recycling-law-map/
Rechargeable Battery Recycling Corporation
Single Chemistry (Lead‐Acid) Multiple Chemistries (Lead‐Acid and Ni‐Cd)
California includes primary batteries
Recovery of (Ni, Co, Mn) for steel production (secondary feedstock)
1. Can nano‐enabled products be handled appropriately using the same stewardship collection infrastructure developed for other products, or must manufacturers provide some form of special handling for products containing nano?
2. Does mixing of recyclate from nano‐enabled products impact markets for recycled materials?
3. Does the collection of nano‐enabled products pose particular challenges to household waste facilities run by municipalities in terms of costs, worker health and safety, or public perception?
Nash, Harvard University Bosso, Northeastern University
SWNT Switch Sensors
EMI‐Shielding/ Composites Batteries
0.0E+00
1.0E‐05
2.0E‐05
3.0E‐05
4.0E‐05
5.0E‐05
6.0E‐05
7.0E‐05
8.0E‐05
9.0E‐05
Carcinogens Airborne inorganics
Climate change Ecotoxicity Acidification/ Eutrophication
Land use Fossil fuels
Normalized
impact value
Impact category
Pre‐diffusion CleaningOxidationChrome Gold DepositionPirahna Etch + Rinse CleaningPhotoresist ApplicationBakeEBL MeshPhotoresist DevelopmentElectrophoretic AssemblyPhotoresist StrippingTransferHiPCO SWNT Process
Dahlben and Isaacs, Northeastern University
Sustainability infers need for recycling strategies for both manufacturing scrap and post‐consumer waste
Determine effect of molding cycles on recyclate properties ◦ thermal and/or mechanical degradation? ◦ chemical and physical changes? ◦ decrease in final properties?
Determine maximum number of cycles to maintain the level of quality for secondary materials
Assess potential for worker exposure during recycling processes, such as machining and grinding Zhang, Mead and Bello
University of Massachusetts Lowell
SWNT Switch Sensors
EMI‐Shielding/ Composites Batteries
23
Porte, Bosso and Isaacs, Northeastern University
Siavoshi, Yilmaz, Somu and Busnaina,
Northeastern University
Biosensors Chemical sensors
Conventional Chemical Sensor
(Metal Oxide)
Next Generation Chemical Sensor
(Carbon Nanotube, CNT) VS
Same manufacturing foundation:
Silicon microchip (IC) CMOS Process
Processes unique to metal oxide
semiconductor sensor fabrication
Processes unique to carbon nanotube sensor
fabrication (ex. manufacture and
functionalization of CNTs)
Proposed Advantages: Lower Detection Limits Enhanced Selectivity Lower Operational Temperature Low operation energy consumption Small Size Longer Lifetime
Assessment Input
Pasquinni and Zimmerman, Yale University Eckelman, Northeastern University
Assessment Output • Comparative environmental and human
health impacts throughout the life cycle • Will focus on human toxicity, ecotoxicity,
global warming potential, fossil fuels
Do standard practices for medical waste hold for CNTs?
Steam Sterilization
Incineration
MSW Stream
Walker and Bosso, Northeastern University
Process‐based inventory collection applied to lab‐scale fabrication of CNT applications
Scale‐up estimates allow approximation of possible CNT releases by series of nano‐enabled products ◦ Manufacturing ◦ Use ◦ End‐of‐Life decommission
Opportunity to reduce environmental footprint of nano‐fabrication ◦ Greener design… ◦ Early intervention…
Inventory collection and estimations through the lifecycle will provide data for influence diagrams and help prioritize subsequent research needs.
Air Biotic Soil Water
Nanomaterial Sources
Nano‐enabled Products
Product End of Life
0
Adapted from Wiesner, 2011 ICEIN Plenary Talk
Intermediate Products
Materials scarcity? Energy increase for raw mat’l production? Energy reduction during manufacture? Energy reduction during product use? Dissipation issues at End‐of‐Life?
System analysis needed to inform decisions ‐‐ But system can become quite broad and includes the social context into which the technology evolves…
Can the interdisciplinary community
learn to bridge the gap?
Social Justice Issues
Regulation and Economic Developmt
Enviro-Economic Assessment
EHS Monitoring and Screening
Integrated Systems Approach Required for Appropriate and Efficient Commercialization
Create technological feasibility
Determine best safety practices and screening methods for nanomaterials
Evaluate EHS /economic tradeoffs and impact of possible releases
Promote informed policymaking
Engineering Performance
Advocate productive public discourse
Funded by NSF Award Numbers EEC-0832785 and SNM-1120329
http://www.northeastern.edu/chn/